Asphalt Plant Operation

In a broad sense the asphalt plant operation includes raw material storage and handling, hot mix asphalt production, and maintenance and upkeep of asphalt plant.

Proper functioning of asphalt plants is of utmost importance. Efficient aggregate handling and storage, precise drying and heating of aggregates, accurate asphalt binder storage and heating, advanced control systems, and adherence to environmental considerations, maintenance, and safety measures all contribute to the successful operation of asphalt plants.

By maintaining the integrity of these processes and components, asphalt plants can produce consistent and durable hot mix asphalt mixtures for road construction projects. Proper asphalt plant functioning also ensures the quality, performance, and longevity of the asphalt pavements, contributing to safe and reliable transportation infrastructure.

Raw Material Storage, Stocking and Handling

Raw materials for production of hot mix asphalt includes aggregates of different sizes, asphalt binder (bitumen), filler material and fuel for firing burners. Sufficient stock and proper handling of these materials ensures continuous, smooth and efficient operation of an asphalt plant without any stoppages.

Aggregate should be stockpiled on a clean, dry, stable surface and should not be allowed to become contaminated with foreign materials such as dust, mud, or grass. The stockpiles of the various aggregate sizes should be kept separated—by physical barriers, if necessary—at all times.The stockpiles should be constructed to be free draining to ensure that the moisture content of the aggregate is as low as possible.Care should be exercised during both the stockpiling and removal processes to minimize segregation of the aggregate in each pile.

The plant is equipped with multiple bins to handle the different sizes of virgin aggregate used in the mix.Proper operation of the front-end loader used to charge the cold-feed bins of the asphalt plant can prevent overflow of the aggregate from one bin into another. Overflowing of aggregates in neighbouring bins can significantly alter the gradation of the mix being produced, particularly in a drum-mix plant.

Asphalt binder also known as bitumen is available in bulk in molten state from refineries or in a packed drums. It should be stocked in required quantity and available all the time when the plant is running. Similarly fuel required for firing dryer and bitumen tank burners should be available for continuous plant operation. Both these commodities are hazardous and prone to catch fire so they should be stored in safe environment.

The asphalt / bitumen, in theplant storage tank(s), must be heated to maintain the correct temperature of the asphalt so its viscosity is low enough that it can be pumped and mixed with the heated and dried aggregate.

Operating the Asphalt Mixing Plant for Hot Mix Asphalt Production

Before starting the asphalt mixing plant, follow the check list provided in the operation manual of the S. P. Enterprise to ascertain that al`l requirement is fulfilled and plant is ready to function.

Then there is a logical sequence for starting and shutting down the plant. Following these sequence each plant component should be turned on or off for smooth running. This sequence is also mentioned in the company’s operation manual and known to experienced operator. Our technicians also imparts training on asphalt plant operation to the customer’s operator after the plant installation and commissioning.

The asphalt plant is operated remotely from the control panel housed in heat and dust proof control cabin. Control panel is an integral part of asphalt plant, playing a crucial role in the efficient and precise operation of the entire production process. It is responsible for controlling and monitoring various parameters, ensuring the accurate proportioning of materials, maintaining consistent temperatures, and optimizing the overall performance of the asphalt plant.

At the end of the production, after shutting down the plant, the material on the belt conveyor and the residual depositing inside and outside the dust removal device should be removed and the asphalt pipeline should be cleaned. Operator should carry out daily inspection and maintenance of the asphalt plant according to the instructions.

Asphalt Plant Maintenance and Upkeep

Proper maintenance and upkeep of asphalt hot mix plant is required for its long life, control on frequent breakdowns, maintaining quality of output and controlling the operating cost. Asphalt plant has a routine and scheduled maintenance checklist and it's important to rely on that guide and follow service intervals to ensure that plant is ready to meet the demand as and when required.

Routine maintenance procedures typically include regular inspections to identify any signs of wear and tear, leaks, or other issues that may affect the performance of the plant. This includes inspecting components such as conveyors, motors, belts, and control systems. Proper lubrication of moving parts to minimize friction and prevent equipment failure. Lubrication schedules and procedures are followed to ensure that all relevant components are adequately lubricated. Regular cleaning of equipment, including screens, bins, and ducts, to prevent the buildup of debris and contaminants, which can compromise equipment performance.

Scheduled maintenance should be performed on periodic basis (daily, weekly, monthly, quarterly and yearly) as per the maintenance manual for lubrication, oil refilling, part replacement and repairing. Scheduled maintenance at the asphalt plant helps to prevent failure while also ensuring the facility is running at peak performance.